New Clutch Install Help [Archive]

98DVL

11-09-2001, 07:51 AM

I haven't done one on an AX-5, but I did mine with an AX-15.

They're probably not much different.

Basic steps:

1) Remove transmission. This is easier said than done... but that's what you gotta do. Unbolt the tranny from the engine at the bell housing. Get a transmission jack if you can (some places will rent... I picked one up at Harbor Frieght for $60). You can remove the t-case from the tranny, but that's just added work. Be sure all electrical connections are undone. You'll also have to disengage the shift lever from the top of the tranny. Don't forget to remove the starter and the clutch slave cylinder.

2) Replace clutch. Again, it sounds a bit easier than it is. Remove the old clutch cover. Remove the clutch disc. If your new clutch kit comes with new bearings, remove the pilot bearing (get a pilot bearing removal tool from the Auto Zone loan-a-tool - it's free with a fully refundable deposit. Also be sure to pick up a slide hammer to use with it.):

http://autozone.com/Repair/InsideOurStores/tools/clutch/27059L.jpg

Replace the throw out bearing. Replace the pilot bearing (use a socket the same size as the bearing and carefully tap it back into place. Replace the clutch disc, and replace the clutch cover. Be careful with the bolts so you don't bend the cover. Tighten them a little at a time, in a "star" pattern (or similar shape, depending on how many bolts there are) until you get to the specified torque.

3. Reinstall transmission. Yes, again, this sounds easier than it is.... Just put everything back into place and give it a test drive. Having a buddy certainly helps.

I've probably left out some steps. If you want a real "step-by-step" description of how to do this... pick up a factory service manual. I probably wouldn't have been able to do it all without a FSM. Everyone who works on their own Jeep needs one of these things. They're worth their weight in gold.

Go pick one up (at your dealer, or from thinkjeep.com). It's the best single piece of equipment you can have for your Jeep.

It's $90 well spent.

Be sure and see this other thread for more info (even though it's on the AX-15):

http://www.pirate4x4.com/forum/showthread.php?s=&threadid=10721

Brent


Pirate4x4.Com > Brand Specific Tech > Jeep - Hardcore Tech > New Clutch Install Help PDA : New Clutch Install Help dnorton 11-09-2001, 06:14 AM Has anyone installed a new clutch on a 2.5L with the AX-5 transmission? I have never done this before and going to need some tips and overall procedure. Thanks. 98DVL 11-09-2001, 07:51 AM I haven't done one on an AX-5, but I did mine with an AX-15. They're probably not much different. Basic steps: 1) Remove transmission. This is easier said than done... but that's what you gotta do. Unbolt the tranny from the engine at the bell housing. Get a transmission jack if you can (some places will rent... I picked one up at Harbor Frieght for $60). You can remove the t-case from the tranny, but that's just added work. Be sure all electrical connections are undone. You'll also have to disengage the shift lever from the top of the tranny. Don't forget to remove the starter and the clutch slave cylinder. 2) Replace clutch. Again, it sounds a bit easier than it is. Remove the old clutch cover. Remove the clutch disc. If your new clutch kit comes with new bearings, remove the pilot bearing (get a pilot bearing removal tool from the Auto Zone loan-a-tool - it's free with a fully refundable deposit. Also be sure to pick up a slide hammer to use with it.): http://autozone.com/Repair/InsideOurStores/tools/clutch/27059L.jpg Replace the throw out bearing. Replace the pilot bearing (use a socket the same size as the bearing and carefully tap it back into place. Replace the clutch disc, and replace the clutch cover. Be careful with the bolts so you don't bend the cover. Tighten them a little at a time, in a "star" pattern (or similar shape, depending on how many bolts there are) until you get to the specified torque. 3. Reinstall transmission. Yes, again, this sounds easier than it is.... Just put everything back into place and give it a test drive. Having a buddy certainly helps. I've probably left out some steps. If you want a real "step-by-step" description of how to do this... pick up a factory service manual. I probably wouldn't have been able to do it all without a FSM. Everyone who works on their own Jeep needs one of these things. They're worth their weight in gold. Go pick one up (at your dealer, or from thinkjeep.com). It's the best single piece of equipment you can have for your Jeep. It's $90 well spent. Be sure and see this other thread for more info (even though it's on the AX-15): http://www.pirate4x4.com/forum/showthread.php?s=&threadid=10721 Brent